KR20140057560A - Electric machine module cooling system and method - Google Patents

Abstract

An embodiment of the present invention provides an electromechanical module. The electromechanical module may include a housing capable of forming a mechanical cavity. In some embodiments, the electrical machine can be positioned within the machine cavity. In some embodiments, the electrical machine may include a stator assembly including a potted stator end turn. An end turn member may be positioned within the machine cavity and the end turn member may include a radially inner flange and a radially outer flange extending axially from the central region. The end turn member is constructed and arranged such that the flanges are substantially adjacent the stator end turn. The end turn member may include at least one second member hole disposed through a portion of the central zone.

Description

ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD FIELD OF THE INVENTION [0001]

Priority information

This application claims priority to U.S. Patent Application No. 13 / 220,428, filed August 29, 2011, the entire content of which is incorporated herein by reference.

Generally, an electric machine housed within a mechanical cavity of a housing includes a stator and a rotor. In some electrical machines, the stator may be secured to the housing using a different coupling technique to generally secure the electrical machine within the housing. During operation of the electrical machine, a significant amount of thermal energy may be generated by both the stator and the rotor as well as by other components of the electrical machine. In some electrical machines, the increase in thermal energy may at least partially prevent the coupling of the housing to the stator.

Some embodiments of the present invention provide an electromechanical module. The electromechanical module may include a housing capable of forming a mechanical cavity. In some embodiments, the electrical machine can be positioned within the machine cavity. In some embodiments, the electrical machine may include a stator assembly that may include a stator end turn. In some embodiments, an end turn member may be positioned within the machine cavity and may include a radially inner flange and a radially outer flange extending axially from the central region. In some embodiments, the end turn members can be configured and arranged such that the flanges can be substantially adjacent at least to the stator end turns. In some embodiments, the end turn member may include at least one second member hole disposed to penetrate a portion of the central region.

Some embodiments of the present invention provide an electromechanical module comprising a housing. In some embodiments, the housing may at least partially form a machine cavity, and may include at least one coolant hole disposed through the coolant jacket and a portion of the housing. In some embodiments, the end turn member may be positioned within the machine cavity such that a portion of the end turn member may contact the housing. In some embodiments, the end turn member may include a radially inner flange and a radially outer flange extending axially from the central region. In some embodiments, at least one first member hole may be disposed through a portion of the radially outer flange. In some embodiments, the end turn member may be positioned within the machine cavity such that the first member hole may be substantially immediately adjacent the coolant hole and in fluid communication with the coolant hole.

1 is a cross-sectional view of an electromechanical module according to an embodiment of the present invention.
Figure 2 is a partial cross-sectional view of a portion of an electromechanical module in accordance with an embodiment of the present invention.
Figure 3 is an isometric view of an end turn member in accordance with an embodiment of the present invention.
4 is a partial cross-sectional view of an end turn member according to an embodiment of the present invention.
5 is an isometric view of a stator assembly in accordance with an embodiment of the present invention.

Before describing certain embodiments of the present invention, it should be understood that the present invention is not limited in its application to the details of construction and arrangement of the components described in the following description and illustrated in the following drawings . The invention is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including", "having", or "having" and variations thereon is intended to encompass the items listed there and their equivalents and additions thereto. Unless otherwise defined or limited, the terms "attached," " coupled, "" supported, " and" coupled, "and variations thereon encompass direct and indirect mounting, do. Also, "coupled" and "coupled" are not limited to physical or mechanical connections or couplings.

The following discussion is provided to enable those skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from the embodiments of the invention. Accordingly, the embodiments of the present invention are not intended to be limited to the embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS The following detailed description is read with reference to the drawings, wherein like elements have like reference numerals in different drawings. The drawings that are not necessarily to scale illustrate selected embodiments and are not intended to limit the scope of the embodiments of the invention. Those skilled in the art will recognize that the examples provided herein have many useful variations that fall within the scope of embodiments of the invention.

Figure 1 illustrates an electromechanical module 10 according to one embodiment of the present invention. The electromechanical module 10 may include a housing 12 comprised of a sleeve member 14, a first end cap 16 and a second end cap 18. The electrical machine 20 can be received in the mechanical cavity 22 formed at least partly by the sleeve member 14 and the end caps 16,18. For example, the sleeve member 14 and the end caps 16,18 may be coupled through conventional fasteners (not shown) or other suitable coupling methods to provide at least a portion of the electrical machine 20 within the machine cavity 22 Seal it. In some embodiments, the housing 12 may be comprised of a substantially cylindrical canister and a single end cap (not shown). In addition, in some embodiments, the module housing 12 including the sleeve member 14 and the end caps 16, 18 may include generally preferred thermal conductive properties, such as, but not limited to, aluminum or other metal And may be made of a material that can withstand the operating temperature of the electrical machine in general. In some embodiments, the housing 12 may be fabricated using different methods, including casting, molding, extrusion, and other similar fabrication methods.

The electrical machine 20 may include a stator assembly 26 including a rotor assembly 24, a stator entrant 28 and a bearing 30 and may be disposed about the shaft 34. As shown in FIG. 1, the stator assembly 26 may substantially surround at least a portion of the rotor assembly 24. In some embodiments, the rotor assembly 24 may also include a rotor hub 32 and may have a "hubless" configuration (not shown).

 In some embodiments, the electrical machine 20 may be operably coupled to the module housing 12. For example, the electric machine 20 can be fitted into the housing 12. In some embodiments, the electric machine 20 may be used to provide an interference fit, a shrink fit, or other similar friction-based fit that may at least partially operably couple the electric machine 2 and the housing 12 And can be fitted in the housing 12. For example, in some embodiments, the stator assembly 26 may be shrink-fit within the module housing 12. Also, in some embodiments, the fit can at least partially anchor the stator assembly 26, and thus the electric machine 20, both axially and circumferentially. In some embodiments, during operation of the electrical machine 20, the fit between the stator assembly 26 and the module housing 12 at least partially serves to transfer torque from the stator assembly 26 to the module 12 . In some embodiments, the fit can cause the module 10 to maintain a generally higher torque.

The electric machine 20 can be, without limitation, an electric motor such as a hybrid electric motor, a generator or a vehicle alternator. In one embodiment, the electric machine 20 may be a High Voltage Hairpin (HVH) electric motor or an internal permanent magnet electric motor for a hybrid vehicle application.

Components of the electric machine 20, such as, but not limited to, the rotor assembly 24, the stator assembly 26, and the stator end turn 28, can generate heat during operation of the electric machine 29). These components can be cooled to increase the performance and lifetime of the electric machine 20. [

As shown in FIGS. 1 and 2, in some embodiments, the housing 12 may include a coolant jacket 36. In some embodiments, the housing 12 may include an inner wall 38 and an outer wall 40, and at least a portion of the coolant jacket 36 may be substantially positioned between the walls 38, 40 . For example, in some embodiments, the mechanical cavity 22 may be at least partially formed by the inner wall 38 (e.g., each element of the housing 12 may constitute a portion of the inner wall 38). In some embodiments, the coolant jacket 36 may substantially surround at least a portion of the electric machine 20. More specifically, in some embodiments, the coolant jacket 36 may substantially surround at least a portion of the outer perimeter of the stator assembly 26 that includes the stator end turn 28.

Also, in some embodiments, the coolant jacket 36 may contain a coolant that may include a transmission fluid, ethylene glycol, an ethylene glycol / water mixture, water, oil, motor oil, gas, mist or the like. The coolant jacket 36 may be in fluid communication with a coolant source (not shown) that can compress the coolant before it is dispersed or dispersed in the coolant jacket 36, 36). ≪ / RTI >

Further, in some embodiments, the inner wall 38 may include a coolant hole 42 to allow the coolant jacket 36 to be in fluid communication with the machine cavity 22. In some embodiments, the coolant apertures 42 may be positioned substantially adjacent the stator end turn 28. For example, in some embodiments, as the compressed refrigerant circulates through the coolant jacket 36, at least a portion of the coolant may exit the coolant jacket 36 through the coolant apertures 42 and enter the machine cavity 22 . Also, in some embodiments, the coolant may contact the stator end turn 28, which may result in at least partial cooling. After exiting the coolant bore 42, at least a portion of the coolant may flow through the machine cavity 22 and contact the various module 10 elements, which in some embodiments may be at least part of the module 10 Which may result in cooling.

According to some embodiments of the present invention, the coolant jacket 36 may comprise a number of configurations. In some embodiments, at least a portion of the coolant jacket 36 may extend through the sleeve member 14 a distance that is substantially similar to the axial length of the stator assembly 26. For example, in some embodiments, the axial length of the portion of the coolant jacket 36 may extend at least a distance equal to the axial length of the stator assembly 26 including the stator end turn 28. In some embodiments, a portion of the coolant jacket 36 may be extended to an axial length as desired by the manufacturer and / or end user for cooling.

In some embodiments, a portion of the coolant jacket 36 may also include at least one radially inwardly extending portion 44. For example, in some embodiments, as shown in FIG. 2, the radially inner extension 44 of the coolant jacket 36 may be substantially perpendicular to at least one of the stator end turns 28, The zones may be substantially radially concave. In some embodiments, the radially inner extension 44 may be positioned adjacent to one or both of the stator end turns 28, and may not be positioned adjacent to any of the stator end turns . Also, in some embodiments, the coolant jacket 36 may include radially inwardly extending extensions 44 substantially continuously around at least a portion of the outer diameter of at least one of the stator end turns 28 (i.e., One continuous radially inner extension about a portion of at least one of the end turns 28). In another embodiment, the coolant jacket 36 includes a substantially separate radially inner extension 44 positioned about at least a portion of the outer diameter 27 of at least one set of stator end turns 28 . In some embodiments, the housing 12 may include at least two radially inner extensions 44. For example, in some embodiments, the housing 12 may include two halves that are coupled together at a substantially axially centered position, such that each half of the housing 12 has a radially inner extension 44 ), And the electric machine 20 can be positioned substantially between the two halves.

In some embodiments, the stator end turn 28 may include a generally smaller outer diameter than the stator assembly 26, resulting in a greater distance between the stator end turn 28 and the coolant jacket 36 Can exist. In some embodiments, the radially inner extension 44 of the coolant jacket 36 may improve cooling of the module 10 because the radially inner extension 44 is substantially free Because some of the coolant may circulate relative to the stator end turn 28 relative to the stator end turn 28. [ As a result, in some embodiments, the distance between the coolant and the region rejecting thermal energy (i.e., the stator end turn) can generally be minimized, which can generally lead to increased heat energy transfer.

In some embodiments, the end turn member 46 may at least partially improve the operation of the module 10. In some embodiments, the end turn member 46 may have a substantially annular or ring shape. In other embodiments, the end turn member 46 may be of other shapes, such as square, rectangular, regular polygonal and / or polygonal, and other similar shapes. In some embodiments, the end turn member 46 may be shaped to approximate the general shape of the stator assembly 26 including the stator end turn 28. Moreover, in some embodiments, the end turn member 46 may be of a single structure as shown in Figure 3, while in other embodiments the end turn member 46 may be comprised of a plurality of lower units coupled together . In some embodiments, the end turn member 46 may also be made of a material that can generally tolerate the operating temperature of the electromechanical device, such as, but not limited to, materials that may include generally preferred thermal conductive properties, such as aluminum or other metals Lt; / RTI > In some embodiments, the end turn member 46 may be fabricated using casting, molding, extrusion processing, and other similar manufacturing methods.

In some embodiments, at least a portion of the inner wall 38 of the housing 12 may include an end turn member 46. In some embodiments, the end turn member 46 may be coupled to the inner wall 38 of one of the end caps 16, 18 and / or the sleeve member 14. For example, in some embodiments, the end turn member 46 may be coupled to the inner wall 38 in an interference fit (e.g., press fit), welded, brazed, or otherwise coupled to the inner wall 38 by a coupling method such as a conventional fastener, Lt; / RTI >

In some embodiments, the end turn member 46 includes at least one feature 45 configured and arranged to at least partially enhance the interaction of the end turn member 46 and the housing 12 . For example, in some embodiments, feature 45 may be a hole, recess, groove, flange, extension, or any other similar structure, as shown in FIG. In some embodiments, the feature 45 may be made of a combination of configurations positioned around a portion of the periphery of the end turn member 46. Also, in some embodiments, the features 45 may be of a plurality of orientations, such as radial, axial, circumferential, or any combination thereof. In some embodiments, the inner wall 38 of the housing 12, irrespective of the configuration of the features 45, is provided with a corresponding feature (not shown) configured and arranged to engage the feature 45 of the end turn member 46 (E.g., the feature 45 may accommodate a portion of the features of the housing 12 and / or vice versa), at least contributing to coupling the two elements together. Additionally, in some embodiments, the feature 45 may function substantially as a torque retaining element to help maintain the torque produced by the electric machine 20 during operation. The feature 45 may also serve as an alignment element that contributes to guiding and / or aligning the end turn member 46 during coupling to the housing 12.

In some embodiments of the present invention, the end turn member 46 may be substantially integral with the housing 12. In some embodiments, the housing 12 may be manufactured such that the end turn member 46 extends from the inner wall 38 of the housing 12. [ For example, in some embodiments, the end turn member 46 may be manufactured as part of the housing 12 (e.g., casting, molding, extrusion, etc.) such that the elements are formed substantially simultaneously and are substantially one element. As a further example, in some embodiments, when coupling the end caps 16, 18 together with the sleeve member 14, the end turn member 46 may be configured to substantially couple to the stator assembly 26 substantially as described above The end turn member 46 can be formed substantially integrally with at least one of the end caps 16, 18 and / or the sleeve member 14 so that it can be positioned adjacent thereto. Although the following objects can suggest an integral non-integral end turn member 46, these refer to an embodiment that includes elements of the end turn member 46 that are substantially integral with the substantially integral end turn member 46 It is by no means intended to exclude the example.

In some embodiments, the end turn member 46 may serve to enhance cooling. For example, as described above, in some embodiments, the coolant jacket 36 may include at least one radially inwardly extending portion 44. However, installing the stator assembly 26 within the sleeve member 14 may be complicated due to the relative dimensions of the stator assembly 26 and the stator end turn 28. For example, in some embodiments, the two radially inwardly extending extensions 44 may be located above the two axial sides of the stator assembly 26 because the outer diameter of the end turn 28 is less than the outer diameter of the stator assembly 26 Positioning the stator assembly 26 may be difficult. As a result, in some embodiments, the module 10 includes a radially inwardly extending extension 44 adjacent one axial end of the stator assembly 26 and a radially inwardly extending end portion 44 substantially adjacent the other axial end of the stator assembly 26 Member (46). Thus, in some embodiments, the endtone member 46 may contribute to cooling at least a portion of the stator assembly 26.

In some embodiments, the end turn member 46 may be configured and arranged to direct a portion of the coolant. The end turn member 46 may be configured and arranged to be substantially aligned with at least one of the coolant holes 42 at the time of positioning the end turn member 46 adjacent the electric machine 20. In some embodiments, And may include at least one first member hole (48). Further, in some embodiments, the first member holes 48 may be substantially radially oriented. For example, in some embodiments, when the end-turn member 46 is positioned within the machine cavity 22, a portion of the coolant exiting the coolant hole 42 may pass through the first member hole 48, The turn member 46 may include substantially the same number of first member holes 48 as the coolant holes 42.

In some embodiments, the end turn member 46 may include a radially outer flange 50, a radially inner flange 52, and a central region 54. 2 to 4, in some embodiments the end turn member 46 may be formed such that the flanges 50 and 52 extend from the central zone 54 into the mechanical cavity 22 (e.g., The end turn member 46 may be formed in a "u" shape that is laid down). In some embodiments, the end turn member 46 may be configured such that the radially outer flange 50 and the radially inner flange 52 extend axially from the central zone 54 and thus the stator end turn 28 (E.g., cast, molded, machined, etc.) so that at least a portion of the end turn member 46 can be received within the end turn member 46. For example, in some embodiments, when the end turn member 46 is positioned substantially adjacent the stator assembly 26, the radially outer flange 50 may be substantially spaced from the outer diameter 27 of the stator end turn 28 Can be adjacent. Further, in some embodiments, the stator end turn may include an inner diameter 29. [ In some embodiments, the radially inner flange 52 may be substantially adjacent the inner diameter 29 of the stator end turn, as shown in Figs. 2 and 5. Thus, in some embodiments, the central zone 54 may be substantially adjacent to the axially outermost portion of at least a portion of the stator end turn 28.

Due to the substantially adjacent spatial relationship of the end turn member 46 and the stator end turn 28, in some embodiments the end turn member 46 may at least partially improve thermal energy transfer. In some embodiments, the end turn member 46 may be made of a material that is substantially thermally conductive (e.g., aluminum) as described above. As a result, because the portion of the end turn member 46 can be in thermal communication with at least a portion of the end turn 28 substantially adjacent to a portion of the end turn 28, 20 during the operation of the end-turn. In addition, as described above, in some embodiments, the endtone member 46 may be immediately adjacent (e.g., frictional fit, interference fit, substantially integral, etc.) to the inner wall of the housing 12, May result in improved heat transfer from the end turn 28 to the housing 12 through the end turn member 46 of material.

Also, in some embodiments, the flanges 50, 52 may contribute more to cooling. In some embodiments, the radially outer flange 50 may include a first member hole 48 such that at least a portion of the coolant passes through both the coolant hole 42 and the first member hole 48 And can contact the stator end turns 28. [ In some embodiments, before and / or after at least a portion of the coolant contacts the stator end turn 28, the end turn member 46 is cooled by maintaining at least a portion of the coolant adjacent the end turn 28. In some embodiments, Can be improved.

Further, in some embodiments, at least a portion of the coolant may flow through the gravity into the bottom of the module 10 after entering the machine cavity 22. In some embodiments, the module 10 may include a conventional drainage system (not shown) positioned generally at the bottom of the module 10 such that at least a portion of the coolant flows from the machine cavity 22 It can flow to the drainage system. In some embodiments, the drainage system may be configured to fluidly and mechanically couple the mechanical cavity 22 to a conventional heat exchange element (e.g., a radiator, heat exchanger, etc.) that is integral with the module 10, adjacent to the module, and / (Not shown). In some embodiments, at least a portion of the coolant can circulate through the heat exchange element where at least a portion of the thermal energy can be removed and the coolant can be recycled for further cooling.

For example, in some embodiments, since the flanges 50, 52 and the central section 54 may be substantially adjacent the portion of the end turn 28, the coolant may be pre- and / Can contact the end turn member (46). As a result, the coolant may at least partially accumulate immediately adjacent to the end turn 28 and / or may bounce from the end turn member 46 to the end turn 28. In some embodiments, the end turn member 46 may at least partially improve cooling, irrespective of the mechanism described above, since the end turn member is capable of at least partially cooling at least a portion of the coolant Because it can function to keep it close to the stator end turn 28.

In addition, in some embodiments, the end turn member 46 may conduct at least a portion of the thermal energy received from the stator end turn 28 to the housing. For example, the coolant can conduct a portion of the thermal energy to the end turn member 46 because at least a portion of the coolant contacts the predetermined end turn 28 and flows to the end turn member 26 after receiving a portion of the heat energy therefrom . In addition, in some embodiments, since the end turn member 46 may be integral with the housing 12 and / or coupled to the housing 12, the end turn member 46 may include at least a portion of the thermal energy in the housing 12 12, and the housing can transfer thermal energy to the surrounding environment through convection. In addition, in some embodiments, the housing 12 and / or the end turn member 46 may conduct at least a portion of the thermal energy to the coolant circulating the coolant jacket 36. [

Also, in some embodiments, the end turn member 46 may serve to enhance the operation of the module 10. [ In some embodiments, the end turn member 46 may include a different structure that may be related to the operation and cooling of the module 10. For example, in some embodiments, the end turn member 46 may include various annular shapes, additional holes, slots, other shapes, or a combination thereof to contribute to operation. As a result, in some embodiments, some of these structures may serve to at least partially improve cooling by further increasing the coolant accumulation substantially adjacent to the end turns 28.

Additionally, in some embodiments, the end turn member 46 may reduce manufacturing overhead. For example, in some embodiments, the module 10 may require some of the structures and / or configurations described above for operation (e.g., extra space or other space-related matter proximate the end-turn 28). In some embodiments, by including these features in the housing 12, extra costs may be incurred to alter the manufacturing process of the housing 12. By including some of these features in the end turn member 46, the manufacturing of the housing 12 can be maintained substantially the same, and the structures can be substantially integrated with the end turn member 46. By way of example only, in some embodiments, the end turn member 46 may be positioned within the housing 12 to accommodate certain specific features of the electrical machine 20 (e.g., a particular end turn portion, electrical connection point, 20 of the present invention. Therefore, simple machining can be performed on the housing 12, and cost and manufacturing complexity can be minimized because more complicated machining can be performed on the end turn member 46. [0053]

According to some embodiments of the present invention, the end turn member 46 may improve cooling in a plurality of module 10 configurations. For example, in some embodiments, the coolant jacket 36 may be of a substantially sealed configuration. As a result, the coolant can circulate through the coolant jacket 36, but does not enter the machine cavity 22 through the hole 44. Thus, the coolant does not contact the stator end turn 28, which can affect the cooling of the module 10 in some embodiments.

 In some embodiments, the end turn member 46 can at least partially contribute to cooling the stator end turn 28 when the coolant jacket 36 is in a substantially sealed configuration. For example, in some embodiments, the end turn member 46 may be made of a substantially non-conductive material such that the flanges 50, 52 and the central section 54 are substantially adjacent the end turn 28, . As a result, in some embodiments, at least a portion of the thermal energy generated by the stator end turn 28 may be transferred to the end turn member 46 through convection. Further, in some embodiments, the end turn member 46 may be configured to receive at least a portion of the thermal energy from the housing 12 (as the end turn member 46 may be integral with the housing 12 and / or coupled to the housing 12) 12 and the housing may deliver thermal energy to the ambient environment through the coolant circulating through the convection or coolant jacket 36. [

In some embodiments, the stator end turn 28 may be of a substantially potted configuration. In some embodiments, at least a portion of the stator end turn 28 may be coated, enclosed, or otherwise covered with a potting component that may at least partially enhance the thermal conductivity from the end turn 28. In some embodiments, the potting component may be made of a resin. For example, in some embodiments, the potting component may be comprised of an epoxy resin, but the potting component may be comprised of another resin. In some embodiments, the resin may provide generally suitable dielectric constants, thermal conductivity, thermal expansion, chemical resistance, etc. for use in applications involving module 10 operating temperature and current. For example, in some embodiments the potting component may be converted to a substantially liquid component (e.g., via heating) and may be supplied by gravity to the end turn 28. In some embodiments, the end turn 28 may be configured to provide gravity feed and / or injection, such that the potting component may cover at least a portion of the stator end turn 29 and may be of a shape at least partially corresponding to the shape of the mold. May be previously placed in the mold. As a result, the potted stator end turn 28 may be of a shape and / or configuration desired by the manufacturer and / or end user. In some embodiments, the potting component may be comprised of a two-part mixture so that the first portion of the potting component and the second portion of the potting component are mixed to activate the potting component prior to application to end turn 28 .

In some embodiments, the end turn member 46 may contribute to cooling the stator end turn 28 in the potted configuration. For example, in some embodiments, the potted end turn 28 may be configured and disposed such that the potting component is immediately adjacent the flange 50, 52 and the central section 54 after solidification. As a result, in some embodiments, the potted stator end turn 28 may conduct at least a portion of the thermal energy generated by the stator end turn 28 through the end turn member 46 to the housing 12. For example, as noted above, in some embodiments, at least a portion of the thermal energy generated by the stator end turn 28 may be conducted through the potting component from the end turn 28 to the end turn member 46, May be generally thermally conductive.

In some embodiments, the end turn member 46 may be used to port at least a portion of the stator end turn 28. In some embodiments, the end turn member 46 may serve as a mold that may be used to form the potted stator end turn 28. [ For example, in some embodiments, the stator assembly 26 may be configured such that at least a portion of the stator end turn 28 is located within the end turn member 46 (e.g., the flanges 50, 52 and the central zone 54) Substantially adjacent " to the end-turn member 46). In some embodiments, after positioning the end turn member 46 relative to the stator end turn 28, the potting component may be applied to at least a portion of the stator end turn 28 via at least a portion of the stator end turn, And thus the stator end turn 28 may be substantially enclosed by the potting element as described above. As a result, in some embodiments, the end turn member 46 may contact the stator end turn 28 via the potting component, so that thermal energy can be conducted easily after the potting component has hardened. The end turn member 46 may be used in a potting process prior to, during, and / or after assembly of the module 10. [

In some implementations, the end turn member 46 may include at least one second member hole 56. In some embodiments, the end turn member 46 may include a plurality of second member holes 56 as shown in FIG. In some embodiments, the second member holes 56 may be disposed substantially axially through a portion of the central region 54, as illustrated in FIGS. 2-4. In some embodiments, the second member holes may be arranged at least partially circumferentially with respect to the end turn member 46. [ For example, in some embodiments, second member holes 56 may be arranged in a regular circumferential pattern (e.g., holes 56 positioned at 30 degree intervals) or in an irregular circumferential pattern. Also, in some embodiments, the inner wall of the housing 12 may include at least some second member holes 56 so that at least some embodiments that function without the end turn member 46 may operate as described below .

In some embodiments, at least a portion of the second member hole 56 may function as an expansion joint. In some embodiments, including at least some of the ported stator end turns 28, the second member hole 56 may serve to accommodate the potting component expansion. For example, the generation of thermal energy by at least a portion of the stator end turn 28 during operation of the electrical machine 20 may cause thermal expansion of the potting material. Because of the thermal expansion of the potting component, in some embodiments, force and / or pressure may be applied to at least a portion of the stator end turn 28, the flanges 50, 52 and / or the central zone 54, The member 46 and / or stator end turn 28 may be damaged.

In some embodiments, the second member hole 56 may serve to at least partially relieve the pressure associated with the thermal expansion of the potting component. For example, in some embodiments, at least a portion of the potting component may expand into the first member hole 56 and / or through the first member hole 56 when the potting component expands. As a result, in some embodiments, the force and / or pressure applied to at least a portion of the stator end turn 28 can be at least partially mitigated by the second member hole 56, which is due to thermal expansion of the potting component The risk of damage to the stator end turn 28 and / or the end turn member 46 can be at least partially reduced.

In some embodiments, the second member hole 56 may be used in a potting process. In some implementations, at least a portion of the second member hole 56 may serve as a potting component inlet during the potting process. For example, in some embodiments, the potting component may be gravity fed or injected around at least some portions of the stator end turn 28, as described above. However, in some embodiments, a different amount of potting component may be supplied around the portion of the stator end turn 28 through at least some of the second member holes 56.

Also, in some embodiments, at least some of the second member holes 56 during the potting process may be substantially sealed (not shown) to a sealing structure (not shown) to prevent the potting component from flowing through the second member hole 56 during the potting process (Plugged). Thereafter, once the potting component is substantially solidified (e.g., cured), the sealing structure can be separated and the second member hole 56 can function as an expansion joint, as described above, during operation of the module 10. Further, in some embodiments, the end turn member 46 may be substantially free of at least a portion of the second member hole 56 before being used in the potting process. After the end turn 28 is potted with the potting component, at least a portion of the second member hole 56 may be formed for use as described above.

It will be apparent to those skilled in the art that the present invention has been described above in connection with specific embodiments and examples, but the present invention is not so limited, and many other embodiments, examples, uses, As will be understood by those skilled in the art. The entire disclosure of each patent and publication disclosed herein is incorporated by reference as if each such patent or publication was incorporated herein by reference in its entirety. Various features and advantages of the invention are set forth in the following claims.

Claims (20)

An electromechanical module comprising:
A housing including an inner wall and an outer wall, the housing at least partially defining a mechanical cavity;
A coolant jacket substantially positioned between a portion of the inner wall and a portion of the outer wall;
At least one coolant hole disposed and arranged through a portion of the inner wall and configured and arranged to fluidly couple the coolant jacket and the machine cavity; And
An end turn member positioned within the machine cavity such that at least a portion of the end turn member contacts the inner wall;
, And the end turn member
A radially inner flange and a radially outer flange extending axially from the central region, and
At least one first member hole disposed through a portion of the radially outer flange
Wherein the end turn member is positioned in the machine cavity such that at least one first member hole immediately adjacent to the at least one coolant hole and in fluid communication with the at least one coolant hole. The electromechanical module of claim 1, wherein the end turn member comprises a cast metal. The stator assembly of claim 1, further comprising an electrical machine at least partially enclosed within the housing, wherein the electrical machine includes a stator assembly, the stator assembly includes a stator end turn and the coolant jacket substantially surrounds a portion of the stator assembly The electrical machine module is positioned to be cheap. 4. The electrical machine of claim 3 wherein the end turn member is positioned within the machine cavity such that the radially outer flange is substantially adjacent the outer diameter of the stator end turn and the radially inner flange is substantially adjacent the inner diameter of the stator end turn. Mechanical module. 4. The electromechanical module of claim 3 wherein the axial length of the portion of the coolant jacket is at least substantially equal to the axial length of the stator assembly. 4. The electromechanical module of claim 3, wherein the coolant jacket comprises at least one radially inward extension adjacent at least one of the stator end turns. 4. The electromechanical module of claim 3, wherein at least a portion of the stator end turn is ported to a potting component. The electromechanical module of claim 1, wherein the end-turn member comprises at least one feature selected from the list of holes, recesses, grooves, flanges, and extensions. The electromechanical module of claim 1, wherein the inner wall comprises a plurality of coolant holes. 10. The apparatus of claim 9, wherein the end turn member includes a plurality of first member holes, wherein the end turn member is configured such that a portion of the plurality of first member holes is immediately adjacent at least a portion of the coolant holes, And is positioned to be in fluid communication with the portion. An electromechanical module comprising:
A housing at least partially defining a mechanical cavity;
An electrical machine positioned within the machine cavity and at least partially enclosed within the housing, the stator assembly comprising a stator end turn, the stator end turn comprising at least a portion of the rotor assembly as a potting component, An electric machine; And
An end turn member positioned within the machine cavity and at least in part of the stator end turn and in communication with a portion of the housing,
Wherein the end turn member includes a radially inner flange and a radially outer flange extending axially from the central region,
The end turn member is configured and arranged such that the radially outer flange is substantially adjacent the outer diameter of the stator end turn and the radially outer flange is substantially adjacent the inner diameter of the stator end turn.
And at least one second member hole is disposed through a portion of the central region. 12. The electromechanical module of claim 11, wherein the housing includes an inner wall, an outer wall, and a coolant jacket positioned between a portion of the inner wall and a portion of the outer wall. 13. The electrical machine module of claim 12, wherein the electrical machine is positioned within the housing such that the coolant jacket substantially encases a portion of the stator assembly. 14. The electromechanical module of claim 13, wherein the coolant jacket comprises at least one radially inner extension adjacent at least a portion of the stator end turns. 12. The electromechanical module of claim 11, wherein the end turn member includes a plurality of second member holes. 16. The electrical machine module of claim 15, wherein the plurality of second member holes are configured and arranged to receive a portion of the potting material during operation of the electric machine. 16. The electrical machine module of claim 15, wherein a plurality of second member holes are circumferentially arranged about the end turn member. 12. The electromechanical module of claim 11, wherein the end turn member is substantially integral with at least a portion of the housing. A method of manufacturing an electromechanical module,
Providing a housing including a sleeve member having a coolant jacket and at least one end cap;
Providing an electrical machine including a stator assembly having a stator end turn;
Installing at least a portion of the electrical machine within the housing such that the stator assembly is at least partially enclosed by the coolant jacket;
Providing an end turn member including a radially outer flange, a radially inner flange, and a central zone;
Disposing at least one second member hole to penetrate a portion of the central zone; And
Positioning the end turn member within the housing such that the radially outer flange is substantially adjacent at least the outer diameter of a portion of the stator end turn and the radially inner flange is substantially adjacent at least the inner diameter of the stator end turn
≪ / RTI > 20. The method of claim 19, further comprising porting at least a portion of the stator end turn to a potting component.

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